Insulating wall assembly, and structure including the same

ABSTRACT

An insulating wall assembly including a substantially rectangular framework having opposite interior and exterior sides, the framework including a plurality of vertical support studs mounted to a plurality of horizontal end studs so as to define at least one inner spacing within the framework, the vertical support studs and the horizontal end studs having each opposite front and rear sides corresponding to the interior and exterior sides of the framework. A foam of water-based polyurethane is injected into said at least one inner spacing so as to complete fill the same and provide the wall assembly with insulating capabilities. Outer components are mounted respectively onto the interior and exterior sides of the framework so as to close up the framework and provide the wall assembly with additional insulating capabilities.

FIELD OF THE INVENTION

The present invention relates to an improved wall assembly. More particularly, and in its preferred embodiment, the present invention relates to an insulating wall assembly, similarly to walls pre-manufactured in factories for the construction of residential, commercial or industrial buildings, such as, for example, apartment buildings, garages, family homes, etc. The present invention also relates to a structure, such as a building for example, comprising at least one such wall assembly. The present application claims priority of Canadian patent application No. 2,522,887 dated Oct. 7, 2005, the content of which is incorporated herein by reference.

BACKGROUND OF THE INVENTION

Known to the Applicant are the following U.S. patents and patent applications which describe different wall structures, assemblies and the like: U.S. Pat. Nos. 3,029,501; 3,797,190; 3,885,008; 3,965,635; 4,572,861; 4,694,624; 4,856,244; 4,914,883; 5,765,330; 5,861,119; 6,099,768; 6,247,280 B1; 6,330,775 B1; 6,332,304 B1; 2003/0150183 A1; and 2004/0216401 A1.

Also known to the Applicant is the following Japanese document, namely, JP No. 2004-308297.

It is also well known in the art that standard walls are generally fabricated with insulating wool inside the walls. The wool is generally not as efficient as one would hope for, particularly in very harsh conditions, such as North American winters. For example, standard wool laid within the walls of 40 feet in length reduces its degree of insulation, the latter passing from R20 to R11.

Furthermore, it is known in the art that it is very important for consumers nowadays to have a home as energy sound as possible, while ensuring a respect for the environment that takes on a greater importance in society, that is why the different walls used in the industry also need to meet these different criteria.

In view of the above, and for various different other reasons, there is a need for an improved insulating wall assembly, which by virtue of its design and components, would be able to overcome some of the concerns known in the prior art.

SUMMARY OF THE INVENTION

An object of the present invention is to provide an insulating wall assembly, which by virtue of its design and components, satisfies some of the above-mentioned concerns and is thus an improvement over other related insulating wall assemblies and/or insulating methods known in the prior art.

In accordance with the present invention, the above object is achieved, as will be easily understood, with an insulating wall assembly, such as the one briefly described herein, and such as the one exemplified in the accompanying drawings.

More particularly, according to the present invention, there is provided an insulating wall assembly comprising:

a substantially rectangular framework having opposite interior and exterior sides, the framework comprising a plurality of vertical support studs mounted to a plurality of horizontal end studs so as to define at least one inner spacing within the framework, the vertical support studs and the horizontal end studs having each opposite front and rear sides corresponding to the interior and exterior sides of the framework;

a foam of water-based polyurethane injected into said at least one inner spacing so as to complete fill the same and provide the wall assembly with insulating capabilities; and

outer components mounted respectively onto the interior and exterior sides of the framework so as to close up the framework and provide the wall assembly with additional insulating capabilities.

Preferably, the outer components comprise a polyethylene cover mounted onto the front sides of the studs so as to entirely cover the interior side of the framework.

Preferably also, the outer components comprises a plurality of plates each being mounted respectively onto a front side of a corresponding vertical support stud, and a gypsum panel operatively mounted onto the front sides of the vertical support studs via the plates, an air space being defined between the polyethylene cover and the gypsum panel, said air space providing the wall assembly with additional insulating capabilities.

Preferably also, the outer components comprise a polyisocyanurate panel operatively mounted onto the rear sides of the studs so as to entirely cover the exterior side of the framework.

Preferably also, the plates are provided with AP foil bands.

Preferably also, each inner spacing comprises a traversal dividing stud connected between a pair of adjacent vertical support studs so as to divide said inner spacing into upper and lower inner spacings, said upper and lower inner spacings being completely filled with the foam of water-based polyurethane.

Preferably also, the foam of water-based polyurethane is a foam with open cells, and more particularly, the foam of water-based polyurethane is preferably a semi-rigid ½ pound density pour-in-place polyurethane foam, commercialized under B500™ by DÉMILEC.

Preferably also, the vertical support studs and the horizontal end studs are 2″×6″ studs, the plates are 1″×2″ plates, adjacent vertical support studs are spaced apart from one another by a transversal distance of about 16″, the thickness of the gypsum panel is about ½″, and the thickness of the polyisocyanurate panel is about ½″.

Preferably also, the overall R value of the insulating wall assembly is about R30.

According to yet another aspect of the present invention, there is also provided a structure comprising at least one of the above-mentioned insulating wall assembly, and preferably, a plurality of such insulating wall assemblies.

According to yet another aspect of the present invention, there is also provided a method of assembling the above-mentioned wall assemblies and/or structure.

According to yet another aspect of the present invention, there is also provided a method of mounting the above-mentioned insulating wall assemblies and/or structure.

According to yet another aspect of the present invention, there is also provided a kit for assembling the above-mentioned insulating wall assemblies and/or structure.

According to yet another aspect of the present invention, there is also provided a method for assembling components of the above-mentioned kit.

The objects, advantages and other features of the present invention will become more apparent upon reading of the following non-restrictive description of preferred embodiments thereof, given for the purpose of exemplification only, with reference to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 represents a partial schematic view of an interior side wall assembly according to a preferred embodiment of the present invention.

FIG. 2 represents a partial schematic view of an exterior side wall assembly according to another preferred embodiment of the present invention.

FIG. 3 is a sectional view of a wall assembly according to yet another preferred embodiment of the present invention.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS OF THE INVENTION

In the following description, the same numerical references refer to similar elements. The embodiments shown in the figures are preferred and are namely used for exemplification purposes only.

Moreover, although the present invention was primarily designed for insulating purposes, and particularly for heat insulation purposes, it may be used with other types of objects, for other purposes and in other fields, such as for soundproofing, for example, as apparent to a person skilled in the art. For this reason, expressions such as “insulating”, “wall”, “assembly”, “home”, “residential”, “building”, etc. as used herein should not be taken as to limit the scope of the present invention and includes all other kind of items and/or purposes with which the present invention could be used and may be useful.

Moreover, in the context of the present invention, the expressions “wall”, “structure”, “assembly”, and any other equivalent expressions known in the art will be used interchangeably. Furthermore, the same applies for any other mutually equivalent expressions, such as “vertical” and “horizontal”, as well as “studs” and “plates” for example, as also apparent to a person skilled in the art.

In addition, although the preferred embodiment of the present invention as illustrated in the accompanying drawings comprises various components and although the preferred embodiment of the insulating wall assembly 1 as shown consists of certain geometrical configurations as briefly explained and illustrated herein, not all of these components and geometries are essential to the invention and thus should not be taken in their restrictive sense, i.e. should not be taken as to limit the scope of the present invention. It is to be understood, as also apparent to a person skilled in the art, that other suitable components and cooperations thereinbetween, as well as other suitable geometrical configurations may be used for the insulating wall assembly 1 and corresponding parts according to the present invention, as briefly explained and as can be easily inferred herefrom by a person skilled in the art, without departing from the scope of the present invention.

Broadly described, the insulating wall assembly 1 according to the present invention, as shown in the accompanying drawings, is an improved insulating wall assembly 1 comprising different components, materials, and/or features, interrelated with one another, and destined to be used, preferably, in walls pre-manufactured in factories for the subsequent construction of residential, commercial or industrial buildings, on site, such as, for example, apartment buildings, garages, family homes, etc., as apparent to a person skilled in the art in view of the present description.

As better exemplified in the accompanying drawings, the insulating wall assembly 1 according to the present invention comprises a substantially rectangular framework 3 having opposite interior and exterior sides 3 a,3 b, the framework 3 comprising a plurality of vertical support studs 5 mounted to a plurality of horizontal end studs 7 so as to define at least one inner spacing 9 within the framework 3, the vertical support studs 5 and the horizontal end studs 7 having each opposite front and rear sides 5 a,7 a,5 b,7 b corresponding to the interior and exterior sides 3 a,3 b of the framework 3.

Also according to the present invention, a foam 11 of water-based polyurethane is injected into said at least one inner spacing 9 so as to complete fill the same and provide the wall assembly 1 with insulating capabilities.

The wall assembly 1 also comprises outer components 13 mounted respectively onto the interior and exterior sides 3 a,3 b of the framework 3 so as to close up the framework 3 and provide the wall assembly 1 with additional insulating capabilities.

Preferably, the outer components 13 comprise a polyethylene cover 15 mounted onto the front sides 5 a,7 a of the studs 5,7 so as to entirely cover the interior side 3 a of the framework 3, as better shown in FIG. 3.

Preferably also, the outer components 13 comprises a plurality of plates 17 each being mounted respectively onto a front side 5 a of a corresponding vertical support stud 5, and a gypsum panel 19 operatively mounted onto the front sides 5 a of the vertical support studs 5 via the plates 17, an air space 21 being defined between the polyethylene cover 15 and the gypsum panel 19, said air space 21 providing the wall assembly 1 with additional insulating capabilities.

Preferably also, the outer components 13 comprise a polyisocyanurate panel 23 operatively mounted onto the rear sides 5 b,7 b of the studs 5,7 so as to entirely cover the exterior side 3 b of the framework 3.

Preferably also, the plates 17 are provided with AP foil bands.

Preferably also, each inner spacing 9 comprises a traversal dividing stud 25 connected between a pair of adjacent vertical support studs 5 so as to divide said inner spacing 9 into upper and lower inner spacings 9, said upper and lower inner spacings 9 being completely filled with the foam 11 of water-based polyurethane.

Preferably also, the foam 11 of water-based polyurethane is a foam 11 with open cells, and more particularly, the foam 11 of water-based polyurethane is preferably a semi-rigid ½ pound density pour-in-place polyurethane foam 11, commercialized under B500™ by DÉMILEC.

Preferably also, the vertical support studs 5 and the horizontal end studs 7 are 2″×6″ studs, the plates 17 are 1″×2″ plates, adjacent vertical support studs 5 are spaced apart from one another by a transversal distance d of about 16″, the thickness of the gypsum panel 19 is about ½″, and the thickness of the polyisocyanurate panel 23 is about ½″.

Preferably also, the overall R′ value of the insulating wall assembly 1 is about R30.

As may now be better appreciated, the present invention could be used in the manufacturing of structures comprising pre-fabricated construction components, such as wall panels, floor beams and assembled floors, as well as roof truss structures, and the like, as apparent to a person skilled in the art.

According to a preferred embodiment of the present invention, the proposed product is preferably a wall assembly 1 having been insulated with urethane. As can be easily understood by a person skilled in the art in view of the accompanying figures, and according to the present invention, it is preferably carried out using a semi-rigid ½ pound density foam of polyurethane B500™ pored in place (PIP) which is preferably injected inside the wall, and this, preferably, in the manufacturing or assembling plant, before putting out to construction.

The insulating wall assembly 1 according to the present invention preferably provides several advantages when compared to conventional walls, examples of which are the following: a) ecological (Eco-Logo); b) Energy Star; c) compliant with NOVO-CLIMAT norms; d) improved noise reduction; e) rate of flame propagation no higher than a conventional wall—preferably, this rate of propagation of flame corresponds to the class #1 of American norms; and f) overall insulation of about R30.

As can be also easily understood by a person skilled in the art in view of the accompanying drawings, and the present description, the preferred components and features of the wall assembly 1 according to the present invention are briefly summarized hereinbelow in table form: PREFERRED COMPONENTS AND FEATURES OF THE WALL R Film of outer air 0.17 Vinyl dressing 0.61 ¾″ space of air 1.02 ¾″ coating — ½″ outer gypsum 0.42 Polyurethane foam 20.96 5½″ (2″ x 6″) stud — Vapour barrier — ½″ inner gypsum 0.42 Film of inner air 0.68 Ap panel (Johns Manville) 3.30 100% continuous insulation of inside —

As may now be better appreciated by a person skilled in the art in view of the present description, table and accompanying figures, the use of a plastic foam 11 according to the present invention is advantageous in the measure where it always keeps the same R value irrespectively of the length of the wall, this R value being preferably R20, approximately.

In the same order of ideas, the urethane or the plastic foam 11 is considered an important feature of the present system. Furthermore, the above-mentioned “Ap foil” bands and panels may be considered optional, but are also considered to be more advantageous whenever present from an insulation point of view.

In view of the above described, one may notice also that the present invention is advantageous in that the urethane comprises increased sound proofing capabilities with respect to insulating wool. Furthermore, it is more ecological and enables for a superior water proofing with respect to a conventional walls filled with insulating wool. Furthermore, by incorporating the “Ap foil” bands (urethane panels) in front of the studs 5,7, as better illustrated in the accompanying drawings, this enables to prevent a thermal bridge between the exterior and the interior of the wall assembly 1.

Moreover, as can be easily understood by a person skilled in the art in view of the accompanying drawings, and according to the present invention, the wall assembly 1 is manufactured in factory using a semi-rigid ½ pound density foam of polyurethane B500™ PIP, preferably also with 2″×5″ studs with a 1″ polyisocyanurate panel on the inside portion of the wall, as better illustrated in FIG. 1, and preferably also, with polyisocyanurate panel on the outside portion of the wall, as better illustrated in FIG. 2.

As may now be better appreciated by a person skilled in the art, the present invention is a substantial improvement over the prior art, in that, by virtue of its design and components, the insulating wall assembly 1 is simple and easy to use, as well as simple and easy to manufacture and/or assemble, without compromising the reliability of its components and features. Hence, it may now be better appreciated that the present invention represents important advantages over other related insulating walls known in the prior art, namely in terms of ease of manufacturing or assembling and improved insulation, as well as being more environmentally friendly, as briefly explained hereinabove.

Of course, numerous modifications could be made to the above-described embodiments without departing from the scope of the present invention, as defined in the appended claims. 

1. An insulating wall assembly comprising: a substantially rectangular framework having opposite interior and exterior sides, the framework comprising a plurality of vertical support studs mounted to a plurality of horizontal end studs so as to define at least one inner spacing within the framework, the vertical support studs and the horizontal end studs having each opposite front and rear sides corresponding to the interior and exterior sides of the framework; a foam of water-based polyurethane injected into said at least one inner spacing so as to complete fill the same and provide the wall assembly with insulating capabilities; and outer components mounted respectively onto the interior and exterior sides of the framework so as to close up the framework and provide the wall assembly with additional insulating capabilities.
 2. An insulating wall assembly according to claim 1, wherein the outer components comprise a polyethylene cover mounted onto the front sides of the studs so as to entirely cover the interior side of the framework.
 3. An insulating wall assembly according to claim 2, wherein the outer components comprises a plurality of plates each being mounted respectively onto a front side of a corresponding vertical support stud, and a gypsum panel operatively mounted onto the front sides of the vertical support studs via the plates, an air space being defined between the polyethylene cover and the gypsum panel, said air space providing the wall assembly with additional insulating capabilities.
 4. An insulating wall assembly according to claim 3, wherein the outer components comprise a polyisocyanurate panel operatively mounted onto the rear sides of the studs so as to entirely cover the exterior side of the framework.
 5. An insulating wall assembly according to claim 4, wherein the plates are provided with AP foil bands.
 6. An insulating wall assembly according to claim 5, wherein each inner spacing comprises a traversal dividing stud connected between a pair of adjacent vertical support studs so as to divide said inner spacing into upper and lower inner spacings, said upper and lower inner spacings being completely filled with the foam of water-based polyurethane.
 7. An insulating wall assembly according to claim 6, wherein the foam of water-based polyurethane is a foam with open cells.
 8. An insulating wall assembly according to claim 7, wherein the foam of water-based polyurethane is a semi-rigid ½ pound density pour-in-place polyurethane foam.
 9. An insulating wall assembly according to claim 8, wherein the foam of water-based polyurethane is B500™ foam.
 10. An insulating wall assembly according to claim 9, wherein the vertical support studs and the horizontal end studs are 2″×6″ studs, the plates are 1″×2″ plates, adjacent vertical support studs are spaced apart from one another by about 16″, the thickness of the gypsum panel is about ½″, and the thickness of the polyisocyanurate panel is about ½″.
 11. An insulating wall assembly according to claim 10, wherein the overall R value of the insulating wall assembly is about R30.
 12. A structure at least one insulating wall assembly, each insulating wall assembly comprising: a substantially rectangular framework having opposite interior and exterior sides, the framework comprising a plurality of vertical support studs mounted to a plurality of horizontal end studs so as to define at least one inner spacing within the framework, the vertical support studs and the horizontal end studs having each opposite front and rear sides corresponding to the interior and exterior sides of the framework; a foam of water-based polyurethane injected into said at least one inner spacing so as to complete fill the same and provide the wall assembly with insulating capabilities; and outer components mounted respectively onto the interior and exterior sides of the framework so as to close up the framework and provide the wall assembly with additional insulating capabilities.
 13. A structure according to claim 12, wherein the outer components comprise a polyethylene cover mounted onto the front sides of the studs so as to entirely cover the interior side of the framework.
 14. A structure according to claim 13, wherein the outer components comprises a plurality of plates each being mounted respectively onto a front side of a corresponding vertical support stud, and a gypsum panel operatively mounted onto the front sides of the vertical support studs via the plates, an air space being defined between the polyethylene cover and the gypsum panel, said air space providing the wall assembly with additional insulating capabilities.
 15. A structure according to claim 14, wherein the outer components comprise a polyisocyanurate panel operatively mounted onto the rear sides of the studs so as to entirely cover the exterior side of the framework.
 16. A structure according to claim 15, wherein the plates are provided with AP foil bands.
 17. A structure according to claim 16, wherein each inner spacing comprises a traversal dividing stud connected between a pair of adjacent vertical support studs so as to divide said inner spacing into upper and lower inner spacings, said upper and lower inner spacings being completely filled with the foam of water-based polyurethane.
 18. A structure according to claim 17, wherein the foam of water-based polyurethane is a foam with open cells.
 19. An insulating wall assembly according to claim 18, wherein the foam of water-based polyurethane is a semi-rigid ½ pound density pour-in-place polyurethane foam, commercialized under B500™.
 20. A kit for assembling an insulating wall assembly, comprising: a substantially rectangular framework having opposite interior and exterior sides, the framework comprising a plurality of vertical support studs mountable to a plurality of horizontal end studs so as to define at least one inner spacing within the framework, the vertical support studs and the horizontal end studs having each opposite front and rear sides corresponding to the interior and exterior sides of the framework; a foam of water-based polyurethane injectable into said at least one inner spacing so as to complete fill the same and provide the wall assembly with insulating capabilities; and outer components mountable respectively onto the interior and exterior sides of the framework so as to close up the framework and provide the wall assembly with additional insulating capabilities. 